US6544909B1 - Single ply reinforced roofing membrane - Google Patents

Single ply reinforced roofing membrane Download PDF

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Publication number
US6544909B1
US6544909B1 US09/591,593 US59159300A US6544909B1 US 6544909 B1 US6544909 B1 US 6544909B1 US 59159300 A US59159300 A US 59159300A US 6544909 B1 US6544909 B1 US 6544909B1
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Prior art keywords
polyolefin
membrane
single ply
layers
roofing membrane
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US09/591,593
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Krishna Venkataswamy
Krishna Srinivasan
Li-Ying Yang
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Building Materials Investment Corp
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Building Materials Investment Corp
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Priority to US09/591,593 priority Critical patent/US6544909B1/en
Assigned to BUILDING MATERIALS INVESTMENT CORPORATION reassignment BUILDING MATERIALS INVESTMENT CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SRINIVASAN, KRISHNA, VENKATASWAMY, KRISHNA, YANG, LI-YING
Assigned to BANK OF NEW YORK, THE, AS COLLATERAL AGENT reassignment BANK OF NEW YORK, THE, AS COLLATERAL AGENT GRANT OF SECURITY INTEREST (PATENTS) Assignors: BUILDING MATERIALS CORPORATION OF AMERICA
Priority to MXPA02012037A priority patent/MXPA02012037A/en
Priority to CA2410825A priority patent/CA2410825C/en
Priority to AU2001259347A priority patent/AU2001259347A1/en
Priority to PCT/US2001/014102 priority patent/WO2001096110A1/en
Priority to US10/359,424 priority patent/US20030118852A1/en
Application granted granted Critical
Publication of US6544909B1 publication Critical patent/US6544909B1/en
Priority to US10/627,847 priority patent/US20040157075A1/en
Assigned to BUILDING MATERIALS CORPORATION OF AMERICA reassignment BUILDING MATERIALS CORPORATION OF AMERICA TERMINATION AND RELEASE OF SECURITY INTEREST Assignors: BANK OF NEW YORK, THE
Assigned to CITIBANK, N.A. reassignment CITIBANK, N.A. SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BMCA INSULATION PRODUCTS INC., BUILDING MATERIALS CORPORATION OF AMERICA, BUILDING MATERIALS INVESTMENT CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF LEATHERBACK CORP., GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., SOUTH PONCA REALTY CORP., WIND GAP REAL PROPERTY ACQUISITION CORP.
Assigned to GAF REAL PROPERTIES, INC., SOUTH PONCA REALTY CORP., BUILDING MATERIALS MANUFACTURING CORPORATION, GAF PREMIUM PRODUCTS, INC., GAFTECH CORPORATION, GAF MATERIALS CORPORATION (CANADA), BUILDING MATERIALS CORPORATION OF AMERICA, PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., BMCA INSULATION PRODUCTS, INC., DUCTWORK MANUFACTURING CORPORATION, BUILDING MATERIALS INVESTMENT CORPORATION, LL BUILDING PRODUCTS, INC., GAF LEATHERBACK CORP., WIND GAP REAL PROPERTY ACQUISITION CORP. reassignment GAF REAL PROPERTIES, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: CITIBANK, N.A.
Assigned to DEUTSCHE BANK TRUST COMPANY AMERICAS reassignment DEUTSCHE BANK TRUST COMPANY AMERICAS SECURITY AGREEMENT Assignors: BMCA ACQUISITION INC., BMCA ACQUISITION SUB INC., BMCA FRESNO II LLC, BMCA FRESNO LLC, BMCA GAINESVILLE LLC, BMCA INSULATION PRODUCTS INC., BMCA QUAKERTOWN INC., BUILDING MATERIALS CORPORATION OF AMERICA, BUILDING MATERIALS INVESTMENT CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF LEATHERBACK CORP., GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, HBP ACQUISITION LLC, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., SOUTH PONCA REALTY CORP., WIND GAP REAL PROPERTY ACQUISITION CORP.
Assigned to DEUTSCHE BANK AG NEW YORK BRANCH reassignment DEUTSCHE BANK AG NEW YORK BRANCH SECURITY AGREEMENT Assignors: BMCA ACQUISITION INC., BMCA ACQUISITION SUB INC., BMCA FRESNO II LLC, BMCA FRESNO LLC, BMCA GAINESVILLE LLC, BMCA INSULATION PRODUCTS INC., BMCA QUAKERTOWN INC., BUILDING MATERIALS CORPORATION OF AMERICA, BUILDING MATERIALS INVESTMENT CORPORATION, BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF LEATHERBACK CORP., GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, HBP ACQUISITION LLC, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., SOUTH PONCA REALTY CORP., WIND GAP REAL PROPERTY ACQUISITION CORP.
Assigned to BUILDING MATERIALS CORPORATION OF AMERICA, BMCA ACQUISITION INC., BMCA ACQUISITION SUB INC., BMCA FRESNO II LLC, BMCA FRESNO LLC, BMCA GAINESVILLE LLC, BMCA INSULATION PRODUCTS INC., BMCA QUAKERTOWN INC., BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, HBP ACQUISITION LLC, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., WIND GAP REAL PROPERTY ACQUISITION CORP., SOUTH PONCA REALTY CORP., GAF LEATHERBACK CORP., BUILDING MATERIALS INVESTMENT CORPORATION reassignment BUILDING MATERIALS CORPORATION OF AMERICA RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: DEUTSCHE BANK TRUST COMPANY AMERICAS, AS COLLATERAL AGENT
Assigned to BUILDING MATERIALS CORPORATION OF AMERICA, BMCA ACQUISITION INC., BMCA ACQUISITION SUB INC., BMCA FRESNO II LLC, BMCA FRESNO LLC, BMCA GAINESVILLE LLC, BMCA INSULATION PRODUCTS INC., BMCA QUAKERTOWN INC., BUILDING MATERIALS MANUFACTURING CORPORATION, DUCTWORK MANUFACTURING CORPORATION, GAF MATERIALS CORPORATION (CANADA), GAF PREMIUM PRODUCTS INC., GAF REAL PROPERTIES, INC., GAFTECH CORPORATION, HBP ACQUISITION LLC, LL BUILDING PRODUCTS INC., PEQUANNOCK VALLEY CLAIM SERVICE COMPANY, INC., WIND GAP REAL PROPERTY ACQUISITION CORP., SOUTH PONCA REALTY CORP., GAF LEATHERBACK CORP., BUILDING MATERIALS INVESTMENT CORPORATION reassignment BUILDING MATERIALS CORPORATION OF AMERICA RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: DEUTSCHE BANK AG NEW YORK BRANCH, AS COLLATERAL AGENT
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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/10—Roof covering by making use of flexible material, e.g. supplied in roll form by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C08L23/0869—Acids or derivatives thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C08L23/0892—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms containing monomers with other atoms than carbon, hydrogen or oxygen atoms
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/19—Sheets or webs edge spliced or joined
    • Y10T428/192—Sheets or webs coplanar
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31909—Next to second addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31909—Next to second addition polymer from unsaturated monomers
    • Y10T428/31913—Monoolefin polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/164—Including a preformed film, foil, or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/164—Including a preformed film, foil, or sheet
    • Y10T442/169—Polyolefin film or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/172—Coated or impregnated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/172—Coated or impregnated
    • Y10T442/176—Three or more layers

Definitions

  • This invention relates to single ply reinforced roofing membranes for covering industrial and commercial flat roofs, and, more particularly, to such membranes having significantly improved tensile and seam strength properties.
  • Heat-sealable, reinforced polyolefin-based single ply roofing membranes are composed of base (bottom) and cap (top) polyolefin-based sheets (layers) with a fiber reinforcement scrim (middle) sandwiched between the other two layers.
  • the scrim is the strongest layer in the composite.
  • the roofing membrane is observed to have only low tensile and seam strength properties.
  • a small amount of a highly-flowable, functional-polyolefin is incorporated into one or both polyolefin-based roofing sheets of a single ply roofing membrane to modify the surface polarity of the polyolefin sheets therein.
  • the resulting composite membrane of the invention exhibits substantially improved adhesion between the reinforcement scrim and the polyolefin sheets. As a result, the tensile and seam strengths of the membrane is advantageously increased.
  • a single ply reinforced roofing membrane having significantly improved tensile and seam strengths.
  • the membrane comprises a reinforcement scrim sandwiched between polyolefin cap and base layers, and is particularly characterized in that at least one of these layers includes a functional-polyolefin as additive therein.
  • the thickness of the membrane preferably ranges from 5 to 200 mils, more preferably from 35-90 mils.
  • the single ply reinforced roofing membrane of the invention includes about 0.5-20% by wt. of the functional-polyolefin additive in one of said layers, preferably about 1-10%, and most preferably about 1-5%.
  • the functional polyolefin additive is suitably selected from polyolelfins which have been modified with one or more functional groups, such as carboxyl. epoxy, anhydride, amine, ester, (meth)acrylate and succinimide groups.
  • a maleic anhydride-modified polyolefin (CK Witco), an epoxy-modified polyethylene (Elf Atochem) and methyacrylate terpolymers thereof (Elf) are preferred.
  • Suitable polyolefins are polymers such as polyethylene, polypropylene, terpolymers of ethylene, propylene and diene monomers, ethylene-propylene copolymers, ethylene-butene copolymers, ethylene-hexene copolymers, ethylene-octene copolymers, propylene-C 4-8 alpha-olefin copolymers, metallocene polyolefins and the like.
  • a preferred functional polyolefin for use herein is maleic anhydride-modified polypropylene sold by CK Witco.
  • Cap (top) and base (bottom) sheets (layers) of a standard single ply reinforcement polyolefin roofing membrane was made of 100 parts of polyolefin resins, including conventional ingredients, such as 0-80 parts of fire retardant, 0-20 parts of processing oil, ingredients zinc oxide, UV and thermal stabilizers, carbon black, titanium dioxide and calcium carbonate, as is well known in the art.
  • the ingredients were mixed in an extruder at 200° C. and sheeted to a thickness of about 20-30 mils.
  • a reinforcement scrim then was inserted between the top and bottom sheets, and the three layers were pressed into a 45 mil reinforced single ply membrane.
  • the standard membrane then was tested for tensile strength and seam strength.
  • the top sheet of the polyolefin roof membrane was made of the same ingredients as described in the Standard Example.
  • the bottom polyolefin sheet was admixed with 3 parts by weight of maleic anhydride-polypropylene (CK Witco) before pressing.
  • CK Witco maleic anhydride-polypropylene
  • the compositions were mixed in an extruder at 200° C. and sheeted to thicknesses of about 20-30 mils.
  • a reinforcement scrim was inserted between the top and bottom sheets and the three layers were pressed into a 45 mil single ply reinforced membrane. The resulting membrane was tested for tensile strength and seam strength.
  • Example 1 was repeated except that 2.5 parts by weight of maleic anhydride-polypropylene additive was included in the top sheet of the membrane.
  • Example 1 was repeated except that 1 part of the additive was provided in the bottom layer.
  • Example 1 was repeated except that 5 parts by weight of the additive was present in the bottom layer.

Abstract

A single ply reinforced roofing membrane having advantageous tensile and seam strength comprising a reinforcement scrim sandwiched between polyolefin cap and base layers, characterized in that at least one of said layers includes a functional polyolefin as additive therein.

Description

BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to single ply reinforced roofing membranes for covering industrial and commercial flat roofs, and, more particularly, to such membranes having significantly improved tensile and seam strength properties.
2. Description of the Prior Art
Heat-sealable, reinforced polyolefin-based single ply roofing membranes are composed of base (bottom) and cap (top) polyolefin-based sheets (layers) with a fiber reinforcement scrim (middle) sandwiched between the other two layers. The scrim is the strongest layer in the composite. In order to fully realize the reinforcement properties of the scrim in such a laminate composite, however, it is necessary that excellent adhesion exist between the polyolefin sheets and the scrim. Unfortunately, due to the inherent incompatibility of scrim materials and polyolefins, only relatively poor interfacial adhesion exists between the scrim and polyolefin sheets. As a result, the roofing membrane is observed to have only low tensile and seam strength properties.
Accordingly, it is an object of this invention to modify the surface characteristics of one or both of the polyolefin-based layers in order to improve the interfacial bonding between polyolefin and scrim thus proving roofing membranes having enhanced membrane tensile and seam strengths.
This and other objects and features of the invention will be made apparent from the following description thereof.
SUMMARY OF THE INVENTION
In this invention, a small amount of a highly-flowable, functional-polyolefin is incorporated into one or both polyolefin-based roofing sheets of a single ply roofing membrane to modify the surface polarity of the polyolefin sheets therein. The resulting composite membrane of the invention exhibits substantially improved adhesion between the reinforcement scrim and the polyolefin sheets. As a result, the tensile and seam strengths of the membrane is advantageously increased.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, there is provided a single ply reinforced roofing membrane having significantly improved tensile and seam strengths. The membrane comprises a reinforcement scrim sandwiched between polyolefin cap and base layers, and is particularly characterized in that at least one of these layers includes a functional-polyolefin as additive therein. The thickness of the membrane preferably ranges from 5 to 200 mils, more preferably from 35-90 mils.
Suitably the single ply reinforced roofing membrane of the invention includes about 0.5-20% by wt. of the functional-polyolefin additive in one of said layers, preferably about 1-10%, and most preferably about 1-5%.
The functional polyolefin additive is suitably selected from polyolelfins which have been modified with one or more functional groups, such as carboxyl. epoxy, anhydride, amine, ester, (meth)acrylate and succinimide groups.
These functional groups can affect the surface of the polyolefin sheets so that it can adhere better to the scrim material. A maleic anhydride-modified polyolefin (CK Witco), an epoxy-modified polyethylene (Elf Atochem) and methyacrylate terpolymers thereof (Elf) are preferred.
Suitable polyolefins are polymers such as polyethylene, polypropylene, terpolymers of ethylene, propylene and diene monomers, ethylene-propylene copolymers, ethylene-butene copolymers, ethylene-hexene copolymers, ethylene-octene copolymers, propylene-C4-8 alpha-olefin copolymers, metallocene polyolefins and the like.
A preferred functional polyolefin for use herein is maleic anhydride-modified polypropylene sold by CK Witco.
The invention will now be described in more detail with reference to the following examples.
STANDARD EXAMPLE
Cap (top) and base (bottom) sheets (layers) of a standard single ply reinforcement polyolefin roofing membrane was made of 100 parts of polyolefin resins, including conventional ingredients, such as 0-80 parts of fire retardant, 0-20 parts of processing oil, ingredients zinc oxide, UV and thermal stabilizers, carbon black, titanium dioxide and calcium carbonate, as is well known in the art. The ingredients were mixed in an extruder at 200° C. and sheeted to a thickness of about 20-30 mils. A reinforcement scrim then was inserted between the top and bottom sheets, and the three layers were pressed into a 45 mil reinforced single ply membrane. The standard membrane then was tested for tensile strength and seam strength.
Invention Example 1
The top sheet of the polyolefin roof membrane was made of the same ingredients as described in the Standard Example. In this example, however, the bottom polyolefin sheet, was admixed with 3 parts by weight of maleic anhydride-polypropylene (CK Witco) before pressing. Then, as usual, the compositions were mixed in an extruder at 200° C. and sheeted to thicknesses of about 20-30 mils. Then a reinforcement scrim was inserted between the top and bottom sheets and the three layers were pressed into a 45 mil single ply reinforced membrane. The resulting membrane was tested for tensile strength and seam strength.
Invention Example 2
Example 1 was repeated except that 2.5 parts by weight of maleic anhydride-polypropylene additive was included in the top sheet of the membrane.
Invention Example 3
Example 1 was repeated except that 1 part of the additive was provided in the bottom layer.
Example 4
Example 1 was repeated except that 5 parts by weight of the additive was present in the bottom layer.
Test Results
The tensile and seam strengths of the membranes of Invention Example 1-4, and the Standard Example are given in the Table below.
TABLE
Tensile Strength,* Seam Strength**
Example No. (psi) (lbs/in)
Standard 2047 107
1 3431 160
2 3288 146
3 3018 137
4 3823 141
*within membrane
**between membranes on roof
This results show that substantial increases in tensile and seam strength are achieved in the invention Examples when the functional polyolefin additive was present in either the bottom or the top layers, as compared to the Standard Example, without additive.
While the invention has been described with particular reference to certain embodiments thereof, it will be understood that changes and modification may be made which are within the skill of the art. Accordingly, it is intended to be bound only by.the following claims, in which:

Claims (1)

What is claimed is:
1. A single ply reinforced roofing membrane comprising a reinforcement scrim sandwiched between cap and base layers which are pressed into a single ply membrane with a thickness of 35-90 mils, characterized in that said layers both are made of ethylene-butene copolymers, with at least one including 1-5 wt. % of maleic anhydride-modified polypropylene as additive therein, said membrane having a tensile strength of 3,018-3,823 psi, and a seam strength of 137-160 lbs/in.
US09/591,593 2000-06-09 2000-06-09 Single ply reinforced roofing membrane Expired - Lifetime US6544909B1 (en)

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US09/591,593 US6544909B1 (en) 2000-06-09 2000-06-09 Single ply reinforced roofing membrane
MXPA02012037A MXPA02012037A (en) 2000-06-09 2001-05-02 Single ply reinforced roofing membrane.
CA2410825A CA2410825C (en) 2000-06-09 2001-05-02 Single ply reinforced roofing membrane
AU2001259347A AU2001259347A1 (en) 2000-06-09 2001-05-02 Single ply reinforced roofing membrane
PCT/US2001/014102 WO2001096110A1 (en) 2000-06-09 2001-05-02 Single ply reinforced roofing membrane
US10/359,424 US20030118852A1 (en) 2000-06-09 2003-02-06 Single ply reinforced roofing membrane
US10/627,847 US20040157075A1 (en) 2000-06-09 2003-07-25 Single ply thermoplastic polyolefin (TPO) roofing membranes having superior heat seam peel strengths and low temperature flexibility

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US09/591,593 US6544909B1 (en) 2000-06-09 2000-06-09 Single ply reinforced roofing membrane

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US10/359,424 Abandoned US20030118852A1 (en) 2000-06-09 2003-02-06 Single ply reinforced roofing membrane

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US20050210808A1 (en) * 2004-03-23 2005-09-29 Building Materials Investment Corporation Building membrane
US20050210802A1 (en) * 2004-03-11 2005-09-29 Building Materials Investment Corporation Mechanically embossed single ply roofing membrane for anti-roll blocking
US20050250399A1 (en) * 2004-05-07 2005-11-10 Building Materials Investement Corporation Modified bitumen and thermoplastic composite roofing membrane
US20050282449A1 (en) * 2004-06-16 2005-12-22 Naresh Mehta Universal fleecebacked roofing membrane
US20060014453A1 (en) * 2004-07-14 2006-01-19 Maia Maria L Flexible sign substrate with black in back
US20060270298A1 (en) * 2005-05-25 2006-11-30 Cooley, Incorporated Textured and printed membrane that simulates fabric
US20060292945A1 (en) * 2005-06-28 2006-12-28 Building Materials Investment Corporation Alternate/reduced scrim for single ply roofing membrane
US20070079926A1 (en) * 2005-10-07 2007-04-12 Mehta Naresh R Methods for printed roofing product
US20070111018A1 (en) * 2003-07-25 2007-05-17 Li-Ying Yang Single ply thermoplastic (tpo) roofing membranes having superior heat seam peel strengths and low temperature flexibility
US20070194482A1 (en) * 2006-02-21 2007-08-23 Bfs Diversified Products, Llc Co-extrusion process for preparing roofing membranes
US7329631B1 (en) 2004-11-09 2008-02-12 Cafepress.Com Method of applying an image to an object
US20090100775A1 (en) * 2007-10-18 2009-04-23 Carlisle Intangible Company Self repairing roof membrane
US20090126411A1 (en) * 2007-11-21 2009-05-21 Brian Callaway Textile-reinforced composites with high tear strength
US20090137168A1 (en) * 2005-08-29 2009-05-28 Richard Peng Thermoplastic roofing membranes
US20090181216A1 (en) * 2006-02-17 2009-07-16 Peng Lichih R Roofing Membranes Including Fluoropolymer
US20090269565A1 (en) * 2006-05-18 2009-10-29 Richard Peng Polymeric laminates including nanoclay
US20100212235A1 (en) * 2009-02-24 2010-08-26 Primesource Building Products Patterned roofing underlayment
US8557078B2 (en) 2008-06-03 2013-10-15 Cafepress Inc. Applique printing process and machine
US8701367B2 (en) * 2002-02-01 2014-04-22 Chem Link, Inc. Roofing system and method
US10907355B2 (en) 2014-04-25 2021-02-02 Firestone Building Products Company, Llc Thermoplastic roofing membranes for fully-adhered roofing systems
US11179924B2 (en) 2014-07-23 2021-11-23 Firestone Building Products Company, Llc Thermoplastic roofing membranes for fully-adhered roofing systems
US11242684B2 (en) 2015-02-06 2022-02-08 Firestone Building Products Company, Llc Thermoplastic roofing membranes for fully-adhered roofing systems
US11555312B2 (en) 2015-12-31 2023-01-17 Holcim Technology Ltd Polyolefin thermoplastic roofing membranes with improved burn resistivity

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WO2015089384A1 (en) * 2013-12-12 2015-06-18 Firestone Building Products Co., LLC Highly loaded thermoplastic membranes with improved mechanical properties
WO2023133504A1 (en) * 2022-01-10 2023-07-13 Bmic Llc Roofing membranes and related methods

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Cited By (33)

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US8701367B2 (en) * 2002-02-01 2014-04-22 Chem Link, Inc. Roofing system and method
US20070111018A1 (en) * 2003-07-25 2007-05-17 Li-Ying Yang Single ply thermoplastic (tpo) roofing membranes having superior heat seam peel strengths and low temperature flexibility
US7651780B2 (en) * 2003-07-25 2010-01-26 Building Materials Investments Corporation Single ply thermoplastic (TPO) roofing membranes having superior heat seam peel strengths and low temperature flexibility
US20050210802A1 (en) * 2004-03-11 2005-09-29 Building Materials Investment Corporation Mechanically embossed single ply roofing membrane for anti-roll blocking
US8347576B2 (en) 2004-03-11 2013-01-08 Building Materials Investment Corporation Mechanically embossed single ply roofing membrane for anti-roll blocking
US9446568B2 (en) * 2004-03-23 2016-09-20 Building Materials Investment Corporation Building membrane
US20050210808A1 (en) * 2004-03-23 2005-09-29 Building Materials Investment Corporation Building membrane
US20050250399A1 (en) * 2004-05-07 2005-11-10 Building Materials Investement Corporation Modified bitumen and thermoplastic composite roofing membrane
US20060199453A1 (en) * 2004-05-07 2006-09-07 Building Materials Investment Corporation Modified bitumen and thermoplastic composite roofing membrane
US7169719B2 (en) * 2004-06-16 2007-01-30 Cooley Incorporated Universal fleecebacked roofing membrane
US20050282449A1 (en) * 2004-06-16 2005-12-22 Naresh Mehta Universal fleecebacked roofing membrane
US20060014453A1 (en) * 2004-07-14 2006-01-19 Maia Maria L Flexible sign substrate with black in back
US7329631B1 (en) 2004-11-09 2008-02-12 Cafepress.Com Method of applying an image to an object
US20060270298A1 (en) * 2005-05-25 2006-11-30 Cooley, Incorporated Textured and printed membrane that simulates fabric
US20060292945A1 (en) * 2005-06-28 2006-12-28 Building Materials Investment Corporation Alternate/reduced scrim for single ply roofing membrane
US20090137168A1 (en) * 2005-08-29 2009-05-28 Richard Peng Thermoplastic roofing membranes
US7749924B2 (en) 2005-08-29 2010-07-06 Bfs Diversified Products, Llc Thermoplastic roofing membranes
US20070079926A1 (en) * 2005-10-07 2007-04-12 Mehta Naresh R Methods for printed roofing product
US20090181216A1 (en) * 2006-02-17 2009-07-16 Peng Lichih R Roofing Membranes Including Fluoropolymer
US20070193167A1 (en) * 2006-02-21 2007-08-23 Bfs Diversified Products, Llc Multi-layer co-extruded roofing membrane
US20070194482A1 (en) * 2006-02-21 2007-08-23 Bfs Diversified Products, Llc Co-extrusion process for preparing roofing membranes
US7882671B2 (en) 2006-02-21 2011-02-08 Bfs Diversified Products, Llc Multi-layer co-extruded roofing membrane
US20090269565A1 (en) * 2006-05-18 2009-10-29 Richard Peng Polymeric laminates including nanoclay
US20090100775A1 (en) * 2007-10-18 2009-04-23 Carlisle Intangible Company Self repairing roof membrane
US20090126411A1 (en) * 2007-11-21 2009-05-21 Brian Callaway Textile-reinforced composites with high tear strength
US7549303B2 (en) 2007-11-21 2009-06-23 Milliken & Company Textile-reinforced composites with high tear strength
US8557078B2 (en) 2008-06-03 2013-10-15 Cafepress Inc. Applique printing process and machine
US20100212235A1 (en) * 2009-02-24 2010-08-26 Primesource Building Products Patterned roofing underlayment
US9982437B2 (en) 2009-02-24 2018-05-29 Primesource Building Products, Inc. Patterned roofing underlayment
US10907355B2 (en) 2014-04-25 2021-02-02 Firestone Building Products Company, Llc Thermoplastic roofing membranes for fully-adhered roofing systems
US11179924B2 (en) 2014-07-23 2021-11-23 Firestone Building Products Company, Llc Thermoplastic roofing membranes for fully-adhered roofing systems
US11242684B2 (en) 2015-02-06 2022-02-08 Firestone Building Products Company, Llc Thermoplastic roofing membranes for fully-adhered roofing systems
US11555312B2 (en) 2015-12-31 2023-01-17 Holcim Technology Ltd Polyolefin thermoplastic roofing membranes with improved burn resistivity

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CA2410825C (en) 2010-07-20
US20030118852A1 (en) 2003-06-26
CA2410825A1 (en) 2001-12-20
WO2001096110A1 (en) 2001-12-20
AU2001259347A1 (en) 2001-12-24

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